EP3681703B1 - Conduction welding - Google Patents

Conduction welding Download PDF

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Publication number
EP3681703B1
EP3681703B1 EP18768890.8A EP18768890A EP3681703B1 EP 3681703 B1 EP3681703 B1 EP 3681703B1 EP 18768890 A EP18768890 A EP 18768890A EP 3681703 B1 EP3681703 B1 EP 3681703B1
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EP
European Patent Office
Prior art keywords
heat sink
welding apparatus
strip
heat
elongate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP18768890.8A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3681703A1 (en
Inventor
Jaap Willem Van Ingen
Marco DOLDERSUM
John Teunissen
Arnt OFFRINGA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GKN Fokker Aerospace BV
Original Assignee
Fokker Aerostructures BV
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Filing date
Publication date
Application filed by Fokker Aerostructures BV filed Critical Fokker Aerostructures BV
Publication of EP3681703A1 publication Critical patent/EP3681703A1/en
Application granted granted Critical
Publication of EP3681703B1 publication Critical patent/EP3681703B1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/30—Electrical means
    • B29C65/32—Induction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
    • B29C65/224—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip being a resistive ribbon, a resistive band or a resistive strip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/348—Avoiding melting or weakening of the zone directly next to the joint area, e.g. by cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81451—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being adaptable to the surface of the joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81455—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81461—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being multi-lamellar or segmented, i.e. comprising a plurality of strips, plates or stacked elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8182—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal insulating constructional aspects
    • B29C66/81821—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal insulating constructional aspects of the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8183—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal conducting constructional aspects
    • B29C66/81831—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal conducting constructional aspects of the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8187—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the electrical insulating constructional aspects
    • B29C66/81871—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the electrical insulating constructional aspects of the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • B29C66/82421—Pneumatic or hydraulic drives using an inflatable element positioned between the joining tool and a backing-up part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91212—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods involving measurement means being part of the welding jaws, e.g. integrated in the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91216—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91231—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the joining tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • B29C66/91423—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools using joining tools having different temperature zones or using several joining tools with different temperatures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B29C66/9292—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams
    • B29C66/92921—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams in specific relation to time, e.g. pressure-time diagrams
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
    • H05B6/14—Tools, e.g. nozzles, rollers, calenders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/863—Robotised, e.g. mounted on a robot arm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3082—Fuselages

Definitions

  • the present invention is concerned with an improved welding apparatus and method for connecting, and specifically welding, composite laminates together.
  • DE 1479840A1 relates to an 'Apparatus and method for cutting and sealing thermoplastic films'.
  • DE 102012215105A1 relates to 'a device for the thermal impulse welding of two plastic components'.
  • Composite laminates are now used widely in the automotive and aerospace industries to provide strong structures with minimal weight.
  • Composite structures such as panels and reinforcement ribs (or the like) can be coupled together in many different ways including conventional couplings such as rivets or nuts and bolts.
  • the present inventors have devised an unconventional welding method and apparatus which allows composite components to be reliably welded together.
  • the technique and method also allows for complex geometries to be welded and furthermore can accommodate local thickness variations and shallow ramps.
  • a void and delamination free weld can thereby be achieved which is highly desirable in aerospace (and other) applications both in terms of aesthetics of the weld and also structural integrity. This is particularly the case for primary structures formed from carbon fibre components in the aerospace industry.
  • a modified and flexible strip is used instead of adopted the conventional approach of using rigid bodies for conduction heating.
  • the flexible strip can follow local thickness variations, even shallow ramps, if properly pressurized and can therefore generate an even weld pressure resulting in void free welds.
  • Advantageously heat sinks are applied next to the welded area to pull the heat out of the laminate. Due to the heat sinks the laminate outside the pressurized zone remains below the melting temperature. This avoids the delamination and consequently voids do not occur.
  • the present invention provides a number of surprising technical and commercial advantages over conventional welding techniques. For example, welding of thermoplastic parts can substantially reduce the number of fasteners which can reduce the weight of the joined component and also save up to 30% on assembly costs.
  • the elongate flexible conductive strip may be any suitable material that can communicate the necessary temperature to melt the resin in the chosen material to be welded.
  • the strip may be an elongate metallic strip such as invar, stainless steel or another suitable high temperature material.
  • the heat sink may be formed of any suitable material and has the function of communicating heat away from the laminate i.e. opposite to the purpose of the conductive strip.
  • the heat sink is generally in the form a 'U' shaped section with a backing portion and two side portions extending away from the back portion. This creates a void in the middle of the heat sink into which the conductive strip and heating means (discussed below) can be positioned.
  • the flexibility i.e. the ability for the heat sink to deflect in a curve along its length (see figure 3 ) may be achieved by partially or completely slicing the heat sink. Slots may thus be formed through the backing portion and along the side portions. Slicing the heat sink in this way creates a series of segments. If the heat sink is then loaded against a curved surface the segments can change angle depending on whether the deformation is a concave deformation or convex deformation. The heat sink can be held together as a single component by limiting the slice or slots to a partial length of each side portion's length.
  • each slot may be typically used to accommodate natural thickness variation in the part surface.
  • the required deformation is very small and so the slot minimum width is only limited by the tool manufacturing requirements.
  • the slots or slices may be formed through the entire depth of the heat sink so as to form a plurality of independent segments. As individual segments the adjacent segments move up and down relative to each other depending on the deformation of the laminate surface.
  • each segment may be electrically insulated from an adjacent segment.
  • eddy currents can be prevented from developing in each segment in an arrangement where an induction coil is used as the heating element.
  • Each side portion of the heat sink is arranged to contact the laminate surface along a distal edge (measured from the base of the U shape). This forms a continuous surface which can be brought into contact with the laminate along the edge or perimeter of the elongate strip - specifically the long sides of the strip. In effect the heat conducting strip is sandwiched between the two edges of the heat sink along its longest edges.
  • edges can collect heat from the laminate during the welding process and advantageously draw heat away from the laminate immediately outside of the weld zone. This prevents heat travelling laterally.
  • the heat sink may be stepped in a manner that seats the strip within the open end of the heat sink.
  • the stepped profile is such that a portion of the flexible strip extends beyond the most distal part of the heat collecting edge.
  • the strip makes contact with the laminate first and begin to soften the resin.
  • the strip then penetrates the surface to a predetermined depth before the heat sink edge abuts with the surface of the laminate and collects heat.
  • the optimum depth values will depend on the specific arrangement and part to be manufactured. In one example a target of 0.1 +/- 0.1mm may be used, to account for tool manufacturing tolerance and to prevent the conductive strip being below the heat sinks
  • the void within the heat sink may be provided with any suitable heat source which can communicate heat to the elongate flexible (and heat conducting) strip.
  • any suitable heat source which can communicate heat to the elongate flexible (and heat conducting) strip.
  • an electrical induction coil may extend along the length of the apparatus.
  • a coil can conveniently follow the deformations caused by the laminate surface profile.
  • An electrical resistance heated rod as a heat source may also be used in conjunction with the invention.
  • the coil may be surrounded by one or more electrical insulators.
  • a pair of insulators may be provided, wherein the first side of the electrical conductor faces the elongate flexible strip and the opposing side of the electrical conductor faces the void within the heat sink.
  • the elongate heat sink, elongate flexible strip, electrical conductor and electrical insulators may be conveniently received in a blind recess formed in a housing of the welding apparatus. As discussed below the blind recess provides:
  • the weld pressure is applied to the backing portion of the heat sink which in turn applies a load, via the stepped portion described above, to the flexible strip.
  • a load via the stepped portion described above, to the flexible strip.
  • the strip and heat sink are brought into contact with the laminate surface using a predetermined pressure.
  • This force can be applied in a variety of ways, for example using actuators, cams or the like.
  • an insulating layer may advantageously be introduced between the heat sink and the hose.
  • thermo-couples In order to monitor the actual temperatures in the weld one or more suitable thermo-couples may be used.
  • a small non-contact pyro meter at the non heated side of the weld may be used to monitor the heat in the material.
  • Use of a temperature sensor may advantageously guarantee a predetermined weld temperature has been reached.
  • thermoplastic based component to a second fibre reinforced resin based component, according to claim 20.
  • a welding apparatus for a thermoplastic based material comprising a flexible elongate heat conductive strip and an associated heat sink extending laterally from the longest edges of the elongate strip, wherein the heat sink is deformable along the length of the strip so as to align in use with deformations in a thermoplastic based material to be welded.
  • thermoplastic based material Viewed from yet another aspect there is provided a welding apparatus for a thermoplastic based material, according to claim
  • a welding apparatus and method may be applied by means of a robotic arm or beam to provide a computer controlled welding process.
  • Figures 1A and 1B illustrate two laminates and the variations between laminate surface geometries. Referring first to Figure 1B , two laminates (L1, L2) are shown which are to be joined (welded) together.
  • the laminates are formed of carbon fibres contained within a thermoplastic resin. These are conventionally known as carbon fibre reinforced thermoplastics (CFRP). It will be recognised that the apparatus and method described herein may equally be applied to other materials using a resin material to entrain fibres.
  • CFRP carbon fibre reinforced thermoplastics
  • Figure 1B illustrates a conventional arrangement for welding the two laminates (L1, L2) together.
  • the simple process involves arranging the two laminates between an upper and lower anvil (AV1, AV2).
  • One of the anvils is heated and the two anvils are biased towards each other to create a welding pressure.
  • the heat is conducted through the anvil to the laminate and the resin within the laminates is caused to melt.
  • the biasing force causes the resins to merge together.
  • the anvils are then released, cooled down and the resin re-hardens or sets and the weld is formed.
  • a conventional welding arrangement such as this has allowed composite laminates to be easily and conveniently joined (welded) together.
  • the laminates are not always perfectly uniform and flat. This is a result of the way in which laminates are formed i.e. as a plurality of individual layers which are then cured together.
  • the result of that manufacturing process is variations in surface profiles resulting in spaces or cavities as illustrates in Figure 1A . Conventionally, these cavities can be accommodated by increasing the biasing pressure or force between the anvils in Figure 1B and/or increasing the temperature or duration of welding. Thus the cavities can be removed.
  • a conventional heater H1 can be seen which is biased or forced towards the opposing anvil AV2 causing laminates L1 and L2 to be forced together.
  • the heater is activated and a weld pool of resin WP is formed which extends through the two laminates L1 and L2.
  • WP weld pool of resin
  • Delamination occurs if the laminate is heated to above the melt temperature without sufficient pressure. This is due to a form of pre-tension or compression in the laminate which is inherited during manufacture of the laminate, which itself is generally performed at high pressure. Furthermore, out-gassing in the resin can create voids if heated to above the melt temperature without a suitable pressure being applied.
  • Figure 2B show the modified welding apparatus 1.
  • the welding tool or apparatus 1 comprises a flexible and elongate metallic (or other heat conductive) strip 2 centrally located in the tool with respect to the weld line.
  • the strip 2 is relatively thin such than it can flex along its length (not shown in figure 2 ). As shown the strip 2 can be brought into contact with a first laminate layer 3, which is itself positioned against a second layer 4, such that the two can be joined i.e. welded together on activation of the tool as described below.
  • the tool comprises a heat sink 5 arranged to surround the strip.
  • the heat sink 5 is in the form of a horizontal upper section 6 and two side section 7a, 7a defining a U shaped cross-section and forming a cavity or space 8 within the heat sink and closed on the lower end by the strip 2.
  • each of the side sections 7a, 7b of the heat sink cooperate with the strip 2 in a stepped manner as shown in Figure 2B .
  • each side section 7a, 7b comprises a first portion which engages with the upper surface of the strip and a section portion which extends down the side of the strip to and is sufficiently long to contact the first laminate 3.
  • the strip 2 is located or housed within the heat sink 7.
  • the strip 2, and heat sink 5 define a first portion 9A of the tool 9A which operates on a first side of the laminates 3, 4 (in figure 2B an upper side).
  • An opposing portion of the tool 9B is arranged on the opposing side of the laminates 3, 4 and provides a surface against which the welding force can be applied.
  • the tool 9B may be a table and the tool 9A may be a movable head mounted on a robotic arm.
  • Figure 2C shows the heat sink in isolation in isometric view, in cross-section and additionally a side elevation of the heat sink.
  • Figure 2C shows the length of the heat sink extending in the z direction.
  • the heat sink comprises a plurality of slits or slots 10 extending from the upper surface 6 towards the ends of the side sections proximate the space which received the strip (not shown in Figure 2C ).
  • the slits or slots 10 divide the heat sink into a plurality of segments 11. All of the segments 11 are connected together at the base of the heat sink 5 where the slits or slots terminate. In effect a portion of the heat sink at the ends of each side section 7a, 7b forms a root which connects the segments together.
  • Each segment 11 has a cross-section as shown in Figure 2B .
  • Figure 2C also shows a side elevation of the heat sink illustrating the uniform spacing of the slits.
  • the precise spacing of the slits (and size of the segments) is dependent on the desired welding characteristics.
  • Figure 2C further shows the stepped profile of the distal ends of the side section of the heat sink with the longer portion arrange (in use) to contact the laminate to be welded which is described in more detail with reference to figure 4 ..
  • Figure 3 shows an enlarged and exaggerated cross-section of the heat sink 5, strip 2 and laminate 3.
  • the cross-section is exaggerated in the curvature of the heat, strip and laminate to illustrate more clearly how the slits 11' between segments 11 allow the heat sink to accommodate an uneven or undulating surface.
  • the heat sink is arranged over a convex profile of an underlying laminate.
  • the segments are permitting to fan or spread out with the slits 11' becoming larger away from the root.
  • the heat sink is arranged over a concave profile of an underlying laminate.
  • the segments are permitted to close together with the slits 11' become smaller away from the root. I will be appreciated that the slits thereby allow the heat sink to accommodate variations in the laminate surface profile whilst maintaining contact with the strip 2 and laminate 3.
  • FIG 3 is an exploded view of heat sink, strip and laminate. It will be recognised that in use the heat sink and flexible strip 2 are coupled together (as described with reference to figure 2B ) and are then brought into contact with the laminate surface 3. As shown, the flexibility of both the heat sink and strip allows them to match the contours of the laminate (exaggerated).
  • FIG. 4 shows the heat sink, strip and insulator of figure 2B in more detail.
  • the heat sink 5 comprises two side portions 7a, 7b which extend towards the flexible strip 2.
  • the ends of the portions 7a, 7b comprise a stepped cross-section which is configured as shown in figure 4 to receive the profile of the conductive strip.
  • the stepped profile could be any geometry which is complimentary to the conductive strip and which can engage with a portion of the strip so as to transfer the welding load onto the strip and consequently onto the laminate.
  • the heat sink 5 and strip 2 are separated by an thermally insulating layer 12 which is located between the conductive strip and the heat sink. This prevents heat passing from the strip 2 into the heat sink itself (which would then itself become heated).
  • Any suitable material may be selected. Suitable examples include a glass fabric, a high temperature resistant coating or a separating material such as a ceramic or the like.
  • the heat sink itself may also be any suitable material such as aluminium or stainless steel or the like.
  • the flexible strip may equally be selected from any suitable material, such as for example steel, invar or stainless steel. More specifically and advantageously the material must be heat resistant to at least 500° C.
  • the stepped cross-section of the end portions of sides 7a, 7b also includes a distal edge 13 which extends all the way along the heat sink (as shown in figure 2C .
  • the distal edge 13 is advantageously arranged so that it does not extend beyond the lowermost surface of the strip 2.
  • the lowermost surface of strip 2 extends a distance S d beyond the lowermost surface of the edge 13.
  • the strip 2 (which is heated, as discussed further below) makes contact with the laminate surface before the edges 13 of the heat sink 5. This allows the strip to heat the laminate without the heat sink slowing the heating process.
  • the welding pressure applied to the top surface 6 causes the strip 2 to penetrate the laminate surface until the edges 13 make contact with the laminate surface.
  • the heat sink begins to absorb heat from the laminate and communicate it away through the side portions 7a, 7b to the main body and root of the heat sink. This is described further with reference to figure 5 .
  • the heat transfer characteristics of the apparatus can be selected depending on the depth distance S d and the ratio of HS w and S w i.e. the ratio of areas of edge portion 13 and strip 2.
  • Figure 5A shows the conventional laminate welding approach in which a heated portion 14 is applied to the laminate 3. As illustrated by arrow X the heat conducts outwards from the weld zone and heats a surrounding area of the laminate. This heating can not only cause delaminations (as discussed above) but also surface irregularities as illustrated by the convex portion in Figure 5A immediately adjacent to the heated portion 14.
  • FIG. 5B is a weld apparatus according to the invention.
  • the strip 2 is insulated from the heat sink 5 by the insulator 12.
  • the strip is brought into contact with the laminate 3 through the weld pressure P.
  • the edge portion 13 of the heart sink is now in contact with the laminate surface immediately adjacent to the weld zone and as shown the weld zone Y constrained beneath the strip 2.
  • excess heat is being prevented from conducting out horizontally but is instead collected by the heat sink and directed away from the laminate (as illustrated by arrow H). This prevents delamination and damage to the lamination around the weld zone.
  • the heat sink aspect of the present welding apparatus alone provides for an improved laminate welding technique.
  • FIG. 6 shows a cross-section of a welding apparatus incorporating the flexible heat sink arrangement described above.
  • a reinforcement rib 3 is being attached to a horizontal laminate surface 4.
  • Like components discussed above are shown in the cross-section of figure 6 , namely the flexible strip 2, insulating layer 12 and heat sink 5. The remaining portions of the welding tool will now be described.
  • the flexible strip 2 conveys heat to the laminate to effect the welding.
  • Heat is provided to the by means of an electrically powered heating element which in the embodiment shown in figure 6 is located in a concave recess formed in the top of the flexible strip 2.
  • An insulator is then located on top of the electrical heating element so that the element is surrounded on a lower half by the concave recess of the strip 2 and on an upper half by a concave recess in the upper insulator 16.
  • the upper insulator insulates the heat sink from the heat generated by the electrical heater.
  • the heater 15, insulator 16 and flexible strip are contained within the space formed within the central area of the heat sink.
  • the electrical element 15 and upper insulator 16 may also be flexible so that they can flex with the strip 2 and heat sink 5 to accommodate variations in laminate surface profile as discussed above with reference to figure 3 .
  • a flexible rubber strip 17 which is positioned between the heat sink 5 and an inflatable rubber hose or bladder 18. These components are all located within a void 19 of the tooling upper housing 20.
  • the inflatable hose is connected to a gas or air supply (not shown) and can be selectively inflated to a predetermined pressure within the void 19. Inflation causes the bladder to expand and apply a force to the upper surface of the rubber strip 17. This in turns applies a force to the upper surface 6 of the heat sink 5 which is itself coupled to the flexible strip. Thus, it can be seen that inflating the hose 18 can selectively apply the weld force to the heat sink and flexible strip 2.
  • the pressure in the hose may be selected depending on the specific configuration.
  • the pressure in the hose may be in the region of 6 bar +/-1 bar.
  • the welding tool house is shown into which the arrangement described above is contained.
  • the housing comprises an upper housing 20 containing the hose 18, rubber strip 17, heat sink 5, insulator 16, electrical heater 15 and flexible strip 2.
  • an upper housing 20 containing the hose 18, rubber strip 17, heat sink 5, insulator 16, electrical heater 15 and flexible strip 2.
  • a second lower housing 21 which acts as a surface against which the welding pressure/force can be applied.
  • the lower housing comprises a heat resistant and insulating surface 22 against which the laminate 4 contacts during welding.
  • the lower housing 21 may be in the form of a lower half of an anvil which is coupled to the upper housing allowing the two to be brought together or separated thereby allowing the laminates to be located between the housing for welding.
  • the lower housing may be in the form of a fixed bed or jig and wherein the upper housing is movable relative thereto.
  • the lower housing/jig can support the laminate at the welding position a variety of arrangements may be possible.
  • the upper housing may be positioned on a robotic arm and the lower housing fixed. Multiple welds in different positions may then be performed.
  • the welding process comprises the following steps:
  • the welding apparatus remains in place until the weld has cooled to a predetermined temperature, for example to below 200° C.
  • Figure 7 show an exploded isometric view of the subcomponents of the apparatus described above. Figure 7 more clearly shows the upper surface of the flexible strip 2 which incorporates a concave portion to receive the heating element 15.
  • Figure 8 shows an isometric view of the tooling in-situ for welding a reinforcing rib 3 to a flat laminate structure 4.
  • the slits which are visible in the exploded view in figure 7 , are hidden behind the upper housing in figure 8 .
  • the width of the slits are selected to be as narrow as possible and are driven by the minimum width of the machine tool (saw blade) which can be used for the chosen material.
  • the depth is a balance between flexibility and durability of the heat sink. Deeper slits result in increased flexibility while reducing durability.
  • the heat conductive strip may also be segmented in the same way.
  • the conductive strip may also closely align with the part surface.
  • FIG 9 shows an alternative configuration of heat sink.
  • the heat sink comprise a plurality of slits which extend from the upper surface of the heat sink down the side portions. The individual segments created by the slits are all coupled together as shown in figure 7 .
  • Figure 9 shows an alternative configuration in which the segments are completely divided i.e. the slits are formed all of the way through the heat sink. This forms a plurality of independent segments making up the heat sink which can each move independently of adjacent segments.
  • dividing the heat sink in this way allows for greater movement of adjacent segments with respect to each other and this allows for greater differences in surface profile of the laminate surface to be accommodated by the welding tool.
  • An electric insulation coating may advantageously be used. Such a coating would be effective to prevent excessive eddy currents in the fully divided heat sink (thus, the heat sink may be prevented from excessive heating due to the induction field in the heater).
  • Another way to prevent excessive eddy currents in the fully divided heat sinks is to limit the contact between the heat sinks to the heat sink corners. This can be done by machining a small recess in the heat sink to heat sink contact surface face while leaving the corners to contact the other heat sinks. Since the corners are far away from the induction coil, electrical contact in the corners causes almost no heating of the heat sink due to the induction field in the heater.
  • Figure 9 illustrates the way in which the flexible heat sink and strip 2 can accommodate larger changes in the thickness of the laminates which are to be welded.
  • the laminate structure comprises a ramp 23 which ramps from first thickness t 1 to a second thickness t 2 .
  • the heat sink 5 is also visible and the continuous contact of the heat sink and laminate can be seen.
  • the flexible strip 2 also follows the contour of the laminate ramp 23.
  • Figure 10 is an exploded view of the arrangement shown in figure 9 .
  • the individual segments of the heat sink 5 can be seen.
  • the flexing of the coil can also be seen corresponding to the change in thickness of the laminate caused by the ram 23.
  • Figure 11 shows a conduction weld graph with time versus temperature and illustrates the temperature of the laminate during the weld process.
  • UD Polyether Ketone Ketone
  • PEKK Polyether Ketone Ketone
  • ⁇ UD' means Uni-Directional and it refers to the pre-preg plies, which consists of fibers in one direction only, as opposed to a fabric (woven) pre-preg layer.
  • UD material is mostly used in primary aircraft structure i.e. parts of the structure that are flight critical.
  • the material melt temperature for this matrix system is approximately 330 0 C and for a good weld 375°C is required, similar to autoclave consolidation of laminates.
  • the surface temperature of the part in contact with the heating element is higher to obtain a temperature gradient over the thickness of the stack i.e. the layers forming the complete laminate. This temperature is limited by the degradation temperature of the PEKK system and is kept below 490°C.
  • the surface temperature of the part which is not in contact with the heating element should preferably remain solid and therefore be ⁇ 330°C.
  • the heat sink is therefore configured to ensure that heat is removed from the weld zone to maintain the surrounding laminate below this temperature.
  • the induction coil frequency was found not to be critical for heating effectivity and the precise power input needed to achieve an optimal weld depends on the length and characteristics of the coil. As examples, both 300kHz and 30kHz can produced good quality welds.
  • weld pressure could also be employed, for example pressure could be applied by a robotic arm or a spring loaded arrangement.
  • the weld pressure can be easily guaranteed by checking the pressure in the pneumatic system. If rubber blocks or springs are used, this is more difficult as the (local) amount of pressure then depends on the amount of compression and the spring stiffness (possible calibration and aging issues). Furthermore if a rubber block is used, heating of the rubber block by carrying out the welding process will create additional expansion, further complicating an even pressure distribution.
  • the hose arrangement provides a number of technical advantages.
  • the heat sink and/or flexible strip may be provided with thermocouples which allow for real time feedback control of the current being applied to the coil. This allows the weld temperature to be accurately controlled according to the desired weld conditions as shown for example in figure 11 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Electromagnetism (AREA)
  • Fluid Mechanics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
EP18768890.8A 2017-09-14 2018-09-12 Conduction welding Active EP3681703B1 (en)

Applications Claiming Priority (2)

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GB201714799A GB2566476B (en) 2017-09-14 2017-09-14 Conduction welding
PCT/EP2018/074655 WO2019053086A1 (en) 2017-09-14 2018-09-12 CONDUCTION WELDING

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JP (1) JP7287737B2 (pt)
CN (1) CN111433006B (pt)
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NL2023583B1 (en) * 2019-07-29 2021-02-22 Bossar Holding B V Production of collapsible pouches having a fitment
NL2023584B1 (en) * 2019-07-29 2021-02-22 Bossar Holding B V Impulse heat sealing of a heat-sealable film material
WO2021018913A1 (en) * 2019-07-29 2021-02-04 Bossar Holding B.V. Impulse heat sealing of a heat-sealable film material
DE102019120595A1 (de) 2019-07-30 2021-02-04 Airbus Operations Gmbh Durchstrahlschweißverfahren, Durchstrahlschweißvorrichtung und Durchstrahlschweißanordnung
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US20200276769A1 (en) 2020-09-03
JP2020533203A (ja) 2020-11-19
CA3075697A1 (en) 2019-03-21
EP3681703A1 (en) 2020-07-22
GB2566476B (en) 2020-01-01
BR112020005023B1 (pt) 2023-11-21
US11845231B2 (en) 2023-12-19
GB201714799D0 (en) 2017-11-01
GB2566476A (en) 2019-03-20
CN111433006A (zh) 2020-07-17
CN111433006B (zh) 2022-11-08
BR112020005023A2 (pt) 2020-09-29
ES2967945T3 (es) 2024-05-06
JP7287737B2 (ja) 2023-06-06

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